International Journal of Scientific & Engineering Research Volume 9, Issue 11, November-2018

ISSN 2229-5518
1719

Enhancement of Multi-loop Level Control with

Optimized Ratio and Split Range Controller using
DCS PCS7
K. POOVENTHAN1, K. SOWNDARYA2, T. MYTHILY3, V. DHARHINI4

Assistant Professor1, PG Student2, Student3, Student4

1,2
Department of Electronics and Instrumentation Engineering, Sri Ramakrishna Engineering College, Coimbatore, Tamil Nadu,
India
Abstract: In the industry, the Paper making process happens to be of multi-loop trainer kit mounted with the
tank whose level is to measured using ratio and split range control. The cascade control is replaced by ratio and
split range control and the flow of the process is the measured inputs to the designed Proportional Integral
Derivative (PID) will be given by the level transmitter. The virtual PID is replaced by hardware PID. The total
outcome of the process is based on the consistency level. The split range control splits the control element over a
particular place as the ratio control segregates by ratio level the result in the consistency level is low so that good
grade quality level papers can be determined. Thus the flexibility and the reconfiguration happens to be a
freedom in the papermaking process.

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Keywords: PID, Paper Making Process, Multi-loop, Cascade control, Ratio control, Split Range Control

INTRODUCTION OVERVIEW OF COMPONENTS

In the industry, the process happens to be of multi-
loop trainer kit mounted with the tank whose level is to
measured using ratio and split range control. The
cascade control is replaced by ratio and split range
control. The flow of the process is the measured inputs
to the designed PID will be given by the level
transmitter. In a cascade control system is taking one
final value as next state initial value whereas the spilt
range control is dividing single set value into two
individual set points. Ratio control system is a
technique where the two various values are given a
single set point correspondingly.
The designed PID will be generating a necessary
controlled electronic signal. The electronic signal is 4-
20mA into a pneumatic signal which is 3-15PSI to
actuate the control value. The virtual PID is replaced
by hardware PID. The total outcome of the process is
based on the consistency level. The split range control
splits the control element over a particular place as the
ratio control segregates by ratio level the result in the
consistency level is low so that good grade quality
level papers can be determined. Thus the flexibility
and the reconfiguration happen to be a freedom in the
papermaking process.
The multi-loop control automation process is controlled
using DCS and PLC. The project involves the usage of
the following components namely,
 Distributed Control System (DCS)
 Programmable Logic Controller (PLC)
 Proportional Integral Derivative (PID)
2.1 Distributed Control System
Generally, the concept of automatic control
includes accomplishing two major operations; the
transmission of signals (information flow) back forth
and the calculation of control actions (decision
making)[2]. This operation requires a set of hardware
and instrumentation which serve as the platform to
perform tasks. It stands as the infrastructure not only
for all advanced control strategies but also for the
lowest control system[3].
The idea of the DCS control system infrastructure is
old. To appreciate and select the current status of
affairs in industrial practice it is of interest to
understand the historical perspective on the evolution
of control systems implementation philosophy and
hardware elements. The evolution concerns the heart of
any control system which is how the information flow
and decision making is advanced.

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International Journal of Scientific & Engineering Research Volume 9, Issue 11, November-2018
ISSN 2229-5518
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2.2 Programmable Logic Controller
The sequential relay control, motion control,
process control, distributed control systems and,
networking is some of the functionality of the PLC. It
is important to note that they have not been generally
accepted in the heavy industry regarding the
practicality of these desktop computer-based logic
controllers. In addition to the, operating systems for
deterministic logic execution will not have hardware
limitations of desktop-based logic with the result in
which the logic may not always respond to changes in
input state or logic status with the extreme consistency
in timing as is expected from PLCs.
2.3 Proportional Integral Derivative Controller
A proportional-integral-derivative controller is
generally used in industrial control systems which is a
generic control loop feedback mechanism. A PID
controller calculates an “error” value which is the
difference between the desired set point and a
measured process variable. The PID controller
algorithm involves three separate constant parameters
these values can be interpreted in terms of time. P
depends on the present error, I on the accumulation of
past errors, and D is a prediction of future errors, based
on the current rate of change. The sum of all three
weighted control actions will adjust the process with a
control element.
SOFTWARE DETAILS SIEMENS (PCS7)
An Instrument and control plant will comprise a
large number of heterogeneous components with
specific parameters and settings. As the plant gets
older, it becomes more difficult to keep track of the
current state of hardware and software. Without system
support, achievement and retention of the required
transparency are furthermore extremely complex. The
current status of the installed hardware and software
components can be called at any time.
PAPER-MAKING PROCESS
Figure 1 shows the flow diagram of the paper
manufacturing process. The pulp is prepared for the

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and based on this sometimes it is known as the three- paper machine including the blending of different
term control that is named as, the proportional(P), the pulps, dilution and the addition of chemicals.
integral(I) and the derivative(D) values. Simply put,
Ground
Mechanical
wood
Pulping
Whitening/B Screening
rightening & cleaning
CTMP/TMP

Pulp
Production Wood yard
Uptakes
Pulping Screening Washing

Chemical
Pulping Bleaching
Waste Paper
Recovery

Coating
Paper
product Stock Wet End Dry end Rewinding Finishing
production Preparation

Paper Product
user

Fig. 1 Flow diagram of the paper manufacturing process

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International Journal of Scientific & Engineering Research Volume 9, Issue 11, November-2018
ISSN 2229-5518
For instance, in the case of pulp being pumped
directly from the pulp mill, the slushing and defacing
stages are omitted. The operations performed in the
paper-making process are Dispersion,
Beating/Refining, Metering, and blending of fiber and
additives. The Cellulosic pulp is manufactured from
the raw materials, using chemical and mechanical
means. Through the mechanical, chemi-mechanical
and chemical methods[5] the pulp for cardboard and
paper can be prepared.
The Multi-loop level process reduces human effort
and increases productivity. Automation in an industry
cultivates innovation with increased system flexibility
and technical risk mitigation. The Multi-loop process is
capable of a small machine control with advanced
features and options. Flexible I/O options to control
and measure a multitude of the process including
various instrumentation parameters and the parameter
taken here is the level.
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SPLIT RANGE CONTROL AND RATIO
CONTROL LOOP
The Multi-loop level deals with the dynamic
systems with the inputs and their behavior is modified
by the feedback. The basic controlling element is the
plant so its output follows the desired control signal,
which monitors the output and compares it with the
reference. The Multi-loop level control over here
works with the multiple loops and generally, the
difference between the actual and desired output is
called the error and in such cases, the stability is
increased.
Fig. 2 Diagram of split range control
In split range control, the output the controller is
split and sent to two or more control valves. In the
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most split range applications, the controller adjusts the
opening of one of the valves when its output is in the
range of 0 to 50 % and the other valve when its output
is in the range of 50 to 100%. The diagram for the spilt
range control is shown in figure 2. The objective of the
ratio control system is to maintain the ratio of two
variables at a specified value. The diagram for the ratio
control loop is shown in figure 3.
Fig. 3 Diagram of ratio control
DCS IMPLEMENTATION ON MULTILOOP
LEVEL CONTROL
In the past, if we found that a number of methods
are there which can be applied to control different
process parameters. Fuzzy logic potentially applicable
to a wide range of processes and a task that normally
require a human experience. In computer normally
values are available in the form of 0 and 1 which will
correspond to either true or false status in the process
parameters normally? Thus the truth values may be
ranges in 0 and 1 in continuous manner fuzzy logic is
the method for representing information in such way
that it the coincidence with the natural human
communication process.
Generally, it is functional and graphical process it’s
having following advanced facility that compact to
contain on or off controller, control algorithm changes
do not call for hardware changes, reduced complexity
and easy to expandability and high speed of the control
of the processing operation. Developing Distributed
Control System is a part the major industrial concern
since those Systems are more and more complex with
the different variable parameter and involved in many
safety-critical applications.
To overcome these difficulties engineers have
developed solutions of their own programming and
supervisory control and data accusation. Computer
International Journal of Scientific & Engineering Research Volume 9, Issue 11, November-2018
ISSN 2229-5518
control is usually carried out in two modes that
supervisory control or direct digital control. The basic
objective in stock preparation is to mix fibrous raw
materials (pulp), non-fibrous components (additives),
and water into a uniform paper making for cup stock
paper. Imported Fibrous raw material cost increasing;
it’s difficult to maintain production cost. For
controlling production cost, planned to consume local
hardwood and bagasse pulp with ratio and split range
controller for achieving the same quality grade paper.
CONCLUSION
Figure 4 shows the overall simulation result of ratio
and split range control. The three main parameters to be
controlled during the paper-making process namely the
level, consistency and vacuum pressure are controlled
using the PLC software.
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Fig. 4 Overall simulation result of ratio and split range
control
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This automation process reduces labor cost and saves
time. Only for the particular range of temperature and
vacuum pressure the consistency value can be
maintained less than or equal to 50 units. Hence those
two parameters are maintained first in order to control
the consistency value of the pulp. The Siemens PCS 7
DCS software is used for simulation purpose and using
the results, the ladder diagram is developed. Hence the
use of PCS 7 DCS in the industry makes the process
efficient and reduces manpower to a greater constraint.
FUTURE SCOPE
The future scope of the automation of Paper-making
process lies in implementing SCADA system for
monitoring the real-time process values from the control
room. The final unusable consistency from the third
boiling system should be made use effectively by using
it in other product manufacturing processes. Hence the
maximum amount of product recovery can be made and
the wastages from the process can be minimized.
ACKNOWLEDMENT
This work was supported and carried out at
Department of Electronics and Instrumentation, Sri
Ramakrishna Engineering College, Coimbatore. We
would like to thank our Management, Director
(Academics), Principal and faculty friends for
supporting us with the infrastructure to carry out the
research work.
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